Power control device



Dec. 3, 1963 J. BONANNO POWER CONTROL nnvrca.

2 Sheets-Sheet 1 Filed Sept. 28, 1959 Til-3-5- INVENTOR z/sep/z Z. Form/100 ATTORNEY Dec. 3, 1963 J. BONANNO POWER CONTROL DEVICE 2 Sheets-Sheet 2 Filed Sept. 28, 1959 INVENTOR Jbsep/r Z. Bonarmo ATTORNEY United States Patent 3,113,258 POWER CONTROL DEVICE Joseph L. Bonanno, South Orange, N.J., assignor, by mesne assignments, to Walter E. Heller & Company (Inc.), New York, N.Y., a corporation of Delaware Filed Sept. 28, 1959, Ser. No. 842,813 14 Claims. (Cl. 321-24) This invention relates in general to an electrical power cont-ruling device and in particular to a power controlling uni-t including a single lever control for both voltage and polarity and including an improved rheostat construction of a portion therein, including a core of highly conductive material over which the resistance wire is wound and which is effective to rapidly dissipate the heat generated in the vicinity of the wire.

The present invention includes a compact arrangement of electrical units for achieving an output range of voltage of direct current and including simple means for varying the range and the polarity of the voltage. The invention finds particular application in the control of model railway trains in which the normal input voltage is in the range of 1 1-5 volts AC. 60 cycles, and the operating voltage of the model railway is between 0 and 14 volts DC. The device includes a compact arrangement of the parts in which .a full wave rectifier is provided including two diode elements mounted on a single plate to convert the input alternating current to direct current. The power control device includes resistance winding wound on spaced quarter annular cores of high heat conductive material, such as copper or anodized aluminum,

arranged within the wiring in order to rapidly dissipate the heat generated in the vicinity thereof. The arrangement includes a sweep arm construction controlled by a single lever mounted on a console type cover which permits control of the voltage output range between 0 and 14 volts of either polarity.

Accordingly, it is an object of this invention to provide an improved power controlling device.

A further object of this invention is to provide an improved power controlling device particularly adapted for use for a model railway, including a compact arrangement of parts and a single lever control for controlling the voltage between certain predetermined limits and for effecting change of polarity over the same voltage control limits.

A further object of this invention is to provide a power control mechanism which is simple in design, rugged in construction and economical to manufacture.

The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this specification.

For a better understanding of the invention, its operating advantages and specific objects obtained by its use, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated and described a preferred embodiment of the invention.

In the drawings:

FIG. 1 is a perspective view of a power control device for a model railway constructed in accordance with the invention;

FIG. 2 is a combination top and bottom plan view of portions of the mechanism with the cover removed and inverted on the left hand side of the figure;

FIG. 3 is a perspective view of the variable resistor and control mechanism for selecting the voltage and polarity;

FIG. 4 is a perspective view of a portion of the transformer and the diode disc having two rectifying areas thereon;

FIG. 5 is a schematic wiring diagram of the power control device; and

3,113,258 Patented Dec. 3, 1963 FIG. 6 is a partial plan view similar to FIG. 2 but showing another embodiment of heat dissipating core.

Referring to the drawings in particular, the invention embodied therein includes a power pack or power control device generally designated 10, particularly constructed for supplying a variable voltage in the control and operation of trains of a model railway.

The power pack 10 includes a mounting base plate '12 over which is positioned a console or cover member generally designated 14. A channel member generally designated 16 is mounted on the base plate 12 and includes laterally extending flanges 13 and 20 horizontally spaced but parallel to the base plate and which support a transformer member 22.

The transformer member 22 is supplied with input power through leads 24 (FIG. 2) which in the present embodiment are designed to receive approximately volts 60 cycles AC. The transformer includes the usual primary coil winding 26 across which the input voltage is applied, and a center tapped secondary coil winding 28 having a sufficient number of coil windings to produce a voltage at terminals 3i and 32 of 16 volts AC. The secondary coil winding 28 is also connected through two diode rectifiers generally designated 34 arranged to produce a direct current voltage of 14 volts D.C. across leads 36 and 38.

The diode rectifier, in accordance with the invention, includes a single plate 40 having two rectifying areas 42 and 44 which are connected by contact members 46 and 48, respectively, to each end of the coil 28. The lower portion of a spring member 78 contacts the center ferrule of plate 49 to provide the electrical connection schematically designated as lead 38 in FIG. 5.

In accordance with the invention, the cover member 1-4 is provided with an insulating boss 50 extending downwardly from the inside top face adjacent one edge thereof. Quarter annular segment core members generally designated 52 and 54 are mounted against the top inner face of the cover member 14 on each side of the insulation 50'. The core members 52 and 54 are held in place by cross contact plates 56 and 58 which are bolted to the cover, and which are spaced from and insulated from one another .at the center of the cover 14. The cross plates 56 and 58 are in electrical contact with the core members 52 and 54, respectively, and are provided with terminal lug connections 60 and '62 which provide a tap for a variable source of direct current voltage. Each of the core members 5 2 and 54 is provided with insulation over which is wound resistance wiring 64 and 66, respectively, the resistance wiring being electrically connected at respective ends to plates 56 and 58, respectively. It should be appreciated that a single core member which is insulated from the resistance wiring and the plates 56 and 58 could be provided. The principal function of the core memhers is to provide a highly conductive heat dissipating mass over which the resistance wiring is wound. In FIG. 6 a one piece core 53 of anodized aluminum to make its surface nonconductive is provided. This one piece core 53 would be used in the same arrangement as indicated in FIG. 2 and resistance wiring 64 and 66 would be wound thereon.

The cover member 14 is also provided with a bearing opening which supports the downwardly extending spindle 68 on which is positioned a contact plate washer 70 which is connected to the terminal 36. In abutting electrical contact with the contact plate 7 0 is a contact sweep arm 72 which is connected to the spindle 68 for rotation therewith as controlled by a handle control 74 which is affixed to the spindle on the outside portion of the cover 14. The sweep arm 72 includes a portion which rides over a preselected one of either resistance wiring 66 or the resistance wiring 64. Suit-able retaining washers 76 are provided to secure the sweep arm to the spindle 68.

Also afiixed to the spindle 63 for rotation therewith, but insulated from the sweep arm 72 by a shoulder thereon, is a contact spring member 78. The contact spring member includes a contact portion 80 which extends through a cutaway portion of the spindle 68 and rests against a predetermined one of either of the contact plates 56 and 58, depending on the position of the control handle 74. The lugs 60 and 62 are integral with contact plates 56 and 58, respectively, and provide taps for the circuit for supplying voltage of either polarity between the range and 14 volts DO The conical portion of the spring member 78 rides the rim of a recessed portion or ferrule of the diode rectifier 34 (FIG. 4) to complete the circuit thereto.

The invention provides a means for controlling both the polarity and the voltage range between 0 and 14 volts DC. by means of a single control handle 74. When the control handle is positioned as indicated in FIG. 1, the sweep arm 72 rests on the insulation 50 and the output voltage is zero. The sweep arm may be advanced either to the left or right into contact with the resistance wiring 64 and 66, and the voltage obtained by the terminals 60 and 62 thereby may be varied between 0 and 14 volts DC. for either forward or reverse operation of a train of a model railway output circuit (not shown), which may be connected to terminals 66 and 62. When the control arm 74 is shifted to the right hand side as viewed in FIG. 1, forward operation of the train may be obtained between varying speeds, and when the arm is shifted to the left, reverse operation of the train may be obtained over a similar range.

As indicated in the circuit wiring diagram in FIG. 5, current may flow through the lead 36 and the portion of the resistance wiring 64 contacted by the arm 72 to the terminal 60.

The other portion of the circuit flows from the lead 38 through the contact arm 80, the plates 58 to the termi nal 62. When current is to be supplied in the opposite direction, the sweep arm 72 is moved into contact with resistance element 66 which automatically brings the contact arm 80 into contact with the contact plate 56. In this latter position, current will flow in the opposite direction, namely, from lead 36, sweep arm 72, resistance wiring 66 to the terminal 62, and from lead 38, contact member 80, contact plate 56 and terminal lug 60.

While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the invention principles, it will be understood that the invention may be embodied otherwise without departing from such principles.

What is claimed is:

l. A power controlling device comprising a source of alternating current, means for rectifying alternating current to direct current connected to said alternating current source, and means connected to said rectifying means for adjusting the magnitude of the direct current and for reversing its polarity, said last mentioned means including a pair of laterally extending terminal output contact plate members spaced from and insulated from one another, a segmental core connected to each of said contact plate terminal members, each of said cores being arranged in complementary arcuate fashion and being spaced from and insulated from one another, first and second resistance wires insulated from but wound respectively around each of said segmental cores, each of said Wires being connected at one end to an associated one of said contact plate members, sweep arm contact means centrally mounted between said segmental core members and including a first portion connected to said rectifying means and arranged to sweep over said resistance wires and a second portion insulated from said first portion connected to said rectifying means and arranged to sweep over an opposite one of said contact terminal plate members.

2. A power control device comprising a mounting plate, a transformer on said mounting plate including primary and secondary coil windings, input high voltage terminals connected to said primary coil windings, first and second terminal means for tapping a predetermined voltage from said secondary coil windings, rectifier means connected across said first terminal means, and means connected to said rectifier means for adjusting the magnitude of the direct current therefrom and for reversing its polarity, said last mentioned means including a pair of complementary first and second core members, first and second resistance windings respectively wound upon said first and second core members but insulated therefrom, a first contact cross plate connected to one end of one of said windings, a second contact across plate connected to an end of the other of said windings, sweep arm control means including a contact portion arranged to sweep over said resistance windings, and a contact arm electrically insulated from said contact portion arranged to sweep over said first plate when said contact portion sweeps over said second resistance winding and arranged to sweep over said second plate when said contact portion sweeps over said first resistance winding, and a control lever for controlling said sweep arm control means.

3. A power control device according to claim 2, wherein said core members are of anodized aluminum.

4. A power control device according to claim 52, wherein said core members are of highly conductive copper.

5. A power control device according to claim 2, wherein said rectifier means includes a single plate with two separated rectifying areas.

6. A power control device comprising a mounting plate, input terminal means for supplying a predetermined alternating current voltage, rectifier means connected across said input terminal means to produce direct current, and means connected to said rectifier means for adjusting the magnitude of the direct current therefrom and for reversing its polarity, said last mentioned means comprising a pair of first and second complementary core members each of highly conductive material and having resistance wiring therearound but insulated therefrom, a first contact cross plate connected to said first core member and to one end of the resistance wiring thereon, a second contact cross plate connected to said second core member and to one end of the resistance wiring thereon, a pivotally mounted contact sweep arm arranged to sweep over a selected one of said first and second core members in contact with said resistance wiring, a contact arm connected to and pivotal with said sweep arm but insulated therefrom arranged to sweep over the opposite one of said contact plates, when said sweep arm is sweeping over said resistance wiring and terminal means connected to said first and second plates for connection to a control circuit.

7. A power control device according to claim 6, including a transformer connected to said input terminals and including primary and secondary coil windings to produce a lower output voltage.

8. A power controlling device comprising input alternating current terminal means, means for rectifying alternating current to direct current connected to said input terminal means, and means connected to said rectifier means for controlling the level and reversing the polarity of the direct current therefrom, said last mentioned means comprising a pair of laterally extending terminal output contact plate members spaced from and insulated from one another, a heat dissipating core member adjacent said contact plate members, first and second coils of resistance wiring insulated from each other and said core and wound around said core, one end of said first coil being connected to one of said plate members and one end of said second coil being connected to the other of said plate members, sweep arm contact means including a first portion connected to one of said input terminals and arranged to sweep over a selected one of said resistance coils and a second portion connected to the other of said input terminals and arranged to sweep over an opposite one of said contact terminal plate members.

9. A power control device comprising a mounting plate, a transformer on said mounting plate including primary and secondary coil windings, input high voltage connected to said primary coil windings, first and second terminal means for tapping a predetermined voltage from said secondary coil windings, rectifier means connected to the first terminal means, and means connected to said rectifier means for controlling the level and reversing the polarity of the direct current output therefrom, said last mentioned means including a core member having first and second resistance wiring wound therearound but insulated therefrom and from each other, a first contact cross plate connected to one end of said first resistance Wiring, a second contact cross plate connected to one end of said second resistance wiring, sweep arm control means including a contact portion connected to said second terminal means arranged to sweep over a selected resistance wiring, and a contact arm arranged to sweep over said first plate when said contact portion sweeps over said second resistance winding and arranged to sweep over said second plate when said contact portion sweeps over said first resistance winding, and a control lever for controlling said sweep arm control means.

10. A power control device according to claim 9, wherein said core member is of anodized aluminum.

11. A power control device according to claim 9, wherein said core member is of highly conductive copper.

12. A power control device according to claim 9, wherein said rectifier means includes a diode having a single disc with two rectifying areas.

13. A power controlling device comprising means for rectifying an alternating current into a direct current; and means connected to said rectifying means for adjusting the magnitude of the direct current and for reversing its polarity; said last mentioned means including, a first portion and a second portion, said first portion comprising, a contact plate member, a segmental core, a resistance wire connected at one end to said plate member Wound about said segmental core and electrically insulated therefrom, said second portion comprising, a contact plate member, a segmental core, a resistance wire connected at one end to said plate member wound about said segmental core and electrically insulated therefrom, said first and second portions being oppositely disposed in arcuate fashion and being spaced and insulated from one another, and sweep arm means pivotally mounted between said first and second portions, said sweep arm means comprising, a first contact portion adapted to make electrical contact with either the resistance wire of said first or of said second portion, and a second contact portion insulated from said first contact portion adapted to make electrical contact with the first portion contact plate member when said first contact portion is in contact with said second portion resistance Wire, and adapted to make electrical contact with the second portion contact plate member when said first contact portion is in contact with said first portion resistance wire.

14. Apparatus according to claim 13, wherein one end of each segmental core is mechanically connected to its respective plate member.

References Cited in the file of this patent UNITED STATES PATENTS 1,778,465 Ozanne Oct. 14, 1930 2,182,865 Franzblau Dec. 12, 1939 2,259,792 Batcheller Oct. 21, 1941 2,266,188 Foley et al. Dec. 16, 1941 2,368,771 Osterheld Feb. 6, 1945 2,430,351 Lidow et a1 Nov. 4, 1947 2,617,911 Carey et al Nov. 11, 1952 2,872,879 Vierling Feb. 10, 1959 2,935,665 Coyle May 3, 1960 2,965,044 Johnson Dec. 20, 1960 

1. A POWER CONTROLLING DEVICE COMPRISING A SOURCE OF ALTERNATING CURRENT, MEANS FOR RECTIFYING ALTERNATING CURRENT TO DIRECT CURRENT CONNECTED TO SAID ALTERNATING CURRENT SOURCE, AND MEANS CONNECTED TO SAID RECTIFYING MEANS FOR ADJUSTING THE MAGNITUDE OF THE DIRECT CURRENT AND FOR REVERSING ITS POLARITY, SAID LAST MENTIONED MEANS INCLUDING A PAIR OF LATERALLY EXTENDING TERMINAL OUTPUT CONTACT PLATE MEMBERS SPACED FROM AND INSULATED FROM ONE ANOTHER, A SEGMENTAL CORE CONNECTED TO EACH OF SAID CONTACT PLATE TERMINAL MEMBERS, EACH OF SAID CORES BEING ARRANGED IN COMPLEMENTARY ARCUATE FASHION AND BEING SPACED FROM AND INSULATED FROM ONE ANOTHER, FIRST AND SECOND RESISTANCE WIRES INSULATED FROM BUT WOUND RESPECTIVELY AROUND EACH OF SAID SEGMENTAL CORES, EACH OF SAID WIRES BEING CONNECTED AT ONE END TO AN ASSOCIATED ONE OF SAID CONTACT PLATE MEMBERS, SWEEP ARM CONTACT MEANS CENTRALLY MOUNTED BETWEEN SAID SEGMENTAL CORE MEMBERS AND INCLUDING A FIRST PORTION CONNECTED TO SAID RECTIFYING MEANS AND ARRANGED TO SWEEP OVER SAID RESISTANCE WIRES AND A SECOND PORTION INSULATED FROM SAID FIRST PORTION CONNECTED TO SAID RECTIFYING MEANS AND ARRANGED TO SWEEP OVER AN OPPOSITE ONE OF SAID CONTACT TERMINAL PLATE MEMBERS. 